Powder dispensing pad

ABSTRACT

A powder dispensing pad comprises a bottom barrier layer, a top barrier layer, a seal circumferentially sealing the top and the bottom barrier layers, a storage layer between the top and bottom barrier layers, and a metering layer having pores between the storage layer and the top barrier layer.

BACKGROUND

Powders have traditionally been dispensed in a variety of ways. Forexample, baby powder and medicated powders have typically been dispensedfrom a bottle, where the top of the bottle contains holes. The bottlecontains enough powder to be dispensed many times.

Cosmetic powders are typically dispensed from a compact, using a brush.The powder is compacted into a solid disk, placed into a plasticcontainer with a lid that snaps shut. The brush is used to loosen asmall amount of powder, which is then transferred from the brush to theskin. The compact contains enough powder to be dispensed many times.

SUMMARY

In a first aspect, the present invention is a powder dispensing pad,comprising (1) a bottom barrier layer, (2) a top barrier layer, (3) aseal, circumferentially sealing the top and the bottom barrier layers,(4) a storage layer, between the top and bottom barrier layers, and (5)a metering layer, having pores, between the storage layer and the topbarrier layer.

In a second aspect, the present invention is a method of making a powderdispensing pad, comprising placing the powder on the bottom barrierlayer; placing a storage layer on the bottom barrier layer, on thepowder; placing the metering layer on the storage layer; placing the topbarrier layer on the metering layer; forming the seal, by pressing thetop barrier layer against the bottom barrier layer and applying heat;and sealing the holes in the top barrier layer by placing the sealinglayer on the top barrier layer.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 depicts a perspective view of a powder dispending pad.

FIG. 2 depicts a cross sectional view of the powder dispensing pad ofFIG. 1 taken along line 1-1.

FIG. 3A depicts a perspective view of the powder dispending pad of FIG.1 without the cover layer.

FIG. 3B depicts an enlarged perspective view of a portion of the powderdispensing pad of FIG. 3A.

FIG. 4 depicts a cross sectional view of a powder dispensing pad.

FIG. 5 depicts a perspective view of a powder dispensing pad.

FIG. 6 depicts a perspective view of a powder dispensing pad.

FIG. 7 depicts a perspective view of a powder dispensing pad in a paddispenser.

FIG. 8 depicts a perspective view of a powder dispensing pad and a paddispenser for dispensing the pad.

FIG. 9 illustrates a flow chart of a method of making a powderdispensing pad.

DETAILED DESCRIPTION

The present invention makes use of the discovery of a powder dispensingpad. The powder dispensing pad includes a bottom barrier layer, and atop barrier layer. The top and bottom barrier layers are sealedtogether, to maintain the powder between them before being dispensed.Inside the powder dispensing pad is a storage layer, with the powderpresent within the storage layer, or the powder being present betweenthe storage layer and the bottom barrier layer. A metering layer havingpores is present between the storage layer and the top barrier layer, toevenly meter out the powder to the top barrier layer. The top barrierlayer includes holes, to dispense the powder. Other optional layers maybe present, including a sealing layer having an adhesive layer, forcovering the holes in the top barrier layer prior to use. The powderdispensing pad may also be in a container, such as a plastic bag, or acontainer for holding a plurality of the powder dispensing pads.

FIG. 1 illustrates a powder dispensing pad, 100, within a container,190, for example a sealed clear plastic bag. The powder dispensing padincludes a top barrier layer, 140, and a bottom barrier layer, 110,which are sealed together, for example at seal 160. The top and bottombarrier layer are made of a material impervious to passage of the powdercontained within the dispenser, and optionally are also a barrier tofluid but allow for the passage of air, or alternatively are gas tight.The top barrier layer includes dispensing holes (not illustrated) whichare covered and sealed by a sealing layer, 150, on the top barrierlayer.

FIG. 2 illustrates a cross-section of the powder dispensing pad, 100,taken along line 1-1 shown in FIG. 1. As illustrated, a powder, 170, isbetween the bottom sealing layer, 110, and a storage layer, 120. Thestorage layer is preferably a very porous non-woven material havingloft. A metering layer, 130, separates the storage layer from the topbarrier layer, 140. The storage layer helps hold the powder within thedispenser, delivering the powder slowly to the metering layer. Themetering layer is preferably made of a material though which the powdercannot pass, except for the presence of pores through which the powdermay pass. The density and size of the pores in the metering layerdetermines how much powder may be dispensed, and ensures that the powderis evenly dispensed across its surface.

Also illustrated in FIG. 2 are optional sublayers of the top and bottombarrier layers, 140 and 110, respectively. Preferably, the top barrierlayer includes an outer fabric sublayer 144 on an inner membrane 142;similarly the bottom barrier layer includes an outer fabric sublayer 114on an inner membrane 112. The outer fabric layers provide a cloth-likefeel to the exterior of the dispenser 100, while the inner membranes,preferably formed from a thin membrane of a polymeric material, preventthe passage of powder and optionally prevent the passage of fluid, orfurther optionally prevent the passage of air. In the case where themembranes contain a thermoplastic polymer film, then the seal, 160, madebe made by heating while pressing the two membranes together. Also shownin FIG. 2 is an adhesive layer, 152, for adhering the sealing layer,150, on the top barrier layer, 140, and the container 190.

FIGS. 3A and 3B illustrates the powder dispensing pad, 100, of FIG. 1,with the sealing layer removed, to reveal more detail of the top barrierlayer, 140, and the metering layer, 130; FIG. 3B is an expanded view ofthe subsection of FIG. 3A labeled “3B”. As show, the top barrier layerincludes a plurality of holes, 146, through which the powder isdispensed. These holes are covered by the sealing layer in FIG. 1.Visible through the holes, 146, is the metering layer, 130, whichincludes pores, 132, which are smaller than the holes in the top barrierlayer. Also illustrated is the seal, 160, and the bottom barrier layer,110.

In a variation, the top barrier layer, bottom barrier layer and the sealbetween them, are all gas tight. Furthermore, the sealing layer and theadhesive layer are also gas tight. When the sealing layer is applied, orwhen the seal is formed, whichever is carried out last, the powderdispensing pad is either flattened using pressure or is placed under lowpressure gas. This will effectively create a vacuum or low pressurewithin the powder dispensing pad, which is maintained until the sealinglayer is removed. Once opened, the storage layer will act as a spring,and expand the powder dispensing pad when the full loft of the storagelayer returns. In this way, the powder dispensing pad will be thinnerduring storage, and prior to use.

As illustrated in FIG. 1, the powder dispensing pad has an oval shape;other shapes, such as a square or a circle, are also possible. The sizeof the dispenser may be any size convenient for the user to hold. Forexample, as shown in FIG. 2, the minor axis of the oval shapeddispenser, W₂, may be for example 3 to 20 cm, more preferably 6 to 14cm, and most preferably 8 to 10 cm, while the major axis (perpendicularto line 1-1 in FIG. 1) may be for example 4 to 27 cm, more preferably 8to 19 cm, and most preferably 11 to 13 cm. The sealing layer covers theholes in the top barrier layer, and is appropriately shaped and sized.As illustrated in FIG. 1, the sealing layer has an oval shape. Forexample, as shown in FIG. 2, the minor axis of the oval shaped sealinglayer, W₁, may be for example 2.25 to 15 cm, more preferably 4.5 to 10.5cm, and most preferably 6 to 7.5 cm, while the major axis (perpendicularto line 1-1 in FIG. 1) may be for example 3 to 20 cm, more preferably 6to 14 cm, and most preferably 8 to 10 cm.

The thickness of the storage layer, illustrated in FIG. 2 as t₁, may befor example 1 to 5 mm, more preferably 2 to 4 mm. The total thickness ofthe dispenser, illustrated in FIG. 2 as t₂, may be for example 0.5 to 5mm greater than the thickness of the storage layer, t₁. The diameter ofthe holes in the top barrier layer, illustrated in FIG. 3B as d₂, may befor example 2 to 10 mm, including 3, 4, 5, 6, 7, 8 and 9 mm. Thediameter of the pores in the metering layer, illustrated in FIG. 3B asd₁, is always less than that of the holes in the top barrier layer, t₂,and may be for example 0.2 to 3 mm, including 0.3, 0.4, 0.5, 0.6, 0.7,0.8, 0.9, 1, 1.25, 1.5, 2 and 2.5 mm. The edge-to-edge distance betweenthe holes in the top barrier layer, illustrated in FIG. 3A as s₂, may besimilar to the diameter of the holes, d₂, and may be for example 2 to 10mm, including 3, 4, 5, 6, 7, 8 and 9 mm. The edge-to-edge distancebetween the pores in the metering layer, illustrated in FIG. 3B as s₁,may be similar to the diameter of the pores, d₁, and may be for example0.2 to 3 mm, including 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, 1, 1.25, 1.5,2 and 2.5 mm.

FIG. 4 illustrates a cross-section of a variation of a powder dispensingpad, similar to powder dispensing pad 100 taken along line 1-1 shown inFIG. 1. In this variation, the powder, 170, is dispersed throughout thestorage layer, 120. Other elements are the same as those illustrated inFIG. 2.

FIG. 5 illustrates another variation of a powder dispensing pad, 100,which does not include a sealing layer. Instead, the powder dispensingpad is folded so that one-half of the top barrier layer, 140, faces theother half of the top barrier layer. A seal, 180, is present on the topbarrier layer, to maintain each half of the top barrier layer againsteach other, to prevent exposure of the holes, 146, and prevent escape ofthe powder. Prior to use, a user may break the seal and unfold thepowder dispensing pad, exposing the holes, 146, to allow for applicationof the powder. Other elements of this variation of a powder dispensingpad are the same as that illustrated in FIGS. 1-4 (except for theabsence of the sealing layer and adhesive layer). The seal, 180, may bemade of the same adhesive as adhesive layer, 152, illustrated in FIG. 2.

FIG. 6 illustrates a cut-away view of another variation of a powderdispensing pad, 100, which does not include a sealing layer, but insteadincludes a cover layer, 350. The cover layer, 350, is on the top barrierlayer, 140, and includes one or more lines of perforations, 380, such asa single line (illustrated), two parallel lines, or two perpendicularlines. The line or lines of perforations have a length which is lessthan a diameter of the top barrier layer, 140, and do not intersect anedge of the cover layer, 350. Prior to use, a user may tug apart theline or lines of perforations, separating the edges of the perforatedline or lines, forming a gap in the cover layer. This gap will exposethe underlying top barrier layer and holes, and the metering layer, toallow the user to dispense the powder.

FIG. 7 illustrates a cut-away view of a pad dispenser, 400, forcontaining a plurality of powder dispensing pads, 100 (although only asingle powder dispensing pad is present in the illustration). The paddispenser, 400, includes a body, 430, and a lid, 420, which is movablyattached to the body. At the top of the body is a top surface, 412, ofthe body which includes an opening, 410, through which a powderdispensing pad may be removed. The opening may have any shape, includinga slit, or cross-shaped slits, as illustrate. In a variation, each ofthe powder dispensing pads may be attached to each other by a weakattachment, so that as a first powder dispensing pad is pulled out ofthe pad dispenser and through the cross-shaped slits, the next powderdispensing pad to which it is attached is pulled part-way through theslits before the weak attachment is broken.

FIG. 8 illustrates a variation of a pad dispenser, 500, for containing aplurality of powder dispensing pads, 100 (although only a singledispenser is present in the illustration). The pad dispenser, 500,includes a body, 530. At the top of the body is a top surface, 512, ofthe body which includes an opening, 510, through which a powderdispensing pad may be removed. The opening as illustrated is a slit. Ina variation, each of the powder dispensing pads may be attached to eachother by a weak attachment, so that as a first powder dispensing pad ispulled out of the pad dispenser and through the slit, the next powderdispensing pad to which it is attached is pulled part-way through theslit before the weak attachment is broken. As illustrated, the powderdispensing pad is part-way through the slit.

FIG. 9 is a flow chart showing a method of making the powder dispensingpad of FIG. 1. In step 900, the powder is applied to the bottom barrierlayer. Next, in step 910, the storage layer is applied onto the powderon the bottom barrier layer. Next, in step 920, the metering layer isapplied to the storage layer. Next, in step 930, the top barrier layercontaining holes is applied to the metering layer. Next, in step 940,the seal is formed by heating and applying pressure along the locationfor the seal. Next, in step 950, the adhesive layer is applied to thesealing layer. Next, in step 960, the sealing layer with the adhesivelayer on it, is applied to the top barrier layer, covering the holes inthe top barrier layer. Lastly, in step 970, optionally the now completedpowder dispensing pad is sealed into a container, such as a plasticpouch.

Variations of the forming process are possible. For example, to form thepowder dispensing pad shown in FIG. 4, steps 900 and 910 are replacedwith two different steps: applying the powder into the storage layer,and then applying the storage layer to the bottom barrier layer. Inanother example, to form the powder dispensing pad shown in FIG. 5,steps 950 and 960 are replaced with two different steps: applying anadhesive in a semicircle along the location of the seal on the topbarrier layer, followed by folding the powder dispensing pad in half.

Any powder may be included in the powder dispensing pad. Examplesinclude baby powder, cosmetic powders, and medicated powders, all ofwhich may be applied to human skin. Preferably, the powder dispensingpad is intended for a single use, and preferably contains only enoughpowder for a single application, referred to as a unit dose. In the caseof a cosmetic powder, the amount of powder is sufficient for a singleapplication, also referred to as a unit dose. In the case of medicatedpowder, a single dosage of the medication is present in the powder, alsoreferred to as a unit dose; when the powder dispensing pad contains aunit dose of medication, the powder dispensing pad may be referred to asa unit dosage form of the medication. In the case of a baby powder, theamount of powder is sufficient for a single application to a baby duringa diaper change. Since not all the powder present in the powderdispensing pad will be dispensed during use, an excess of the powder maybe included so that a unit dose of the powder is dispensed during use.

1. A powder dispensing pad, comprising: (1) a bottom barrier layer, (2)a top barrier layer, (3) a seal, circumferentially sealing the top andthe bottom barrier layers, (4) a storage layer, between the top andbottom barrier layers, (5) a metering layer, having pores, between thestorage layer and the top barrier layer, and (6) a powder, between thebottom barrier layer and the top barrier layer.
 2. The powder dispensingpad of claim 1, further comprising holes in the top barrier layer,through which the powder may be dispensed.
 3. The powder dispensing padof claim 2, further comprising: (7) a sealing layer, on the top barrierlayer and covering the holes, and (8) an adhesive layer, adhering thesealing layer to the top barrier layer.
 4. The powder dispensing pad ofclaim 1, further comprising a container, within which is the powderdispensing pad.
 5. The powder dispensing pad of claim 4, wherein thecontainer is a plastic bag.
 6. The powder dispensing pad of claim 2,wherein the powder dispensing pad is folder in half, so that each halfof the top barrier layer face each other, and a seal on the top barrierlayer, for holding each half of the top barrier layer together.
 7. Thepowder dispensing pad of claim 1, further comprising a cover layerhaving a line of perforations.
 8. The powder dispensing pad of claim 1,wherein the powder is between the bottom barrier layer and the meteringlayer.
 9. The powder dispensing pad of claim 8, wherein the powder isbetween the storage layer and the bottom barrier layer.
 10. The powderdispensing pad of claim 8, wherein the powder is within the storagelayer.
 11. The powder dispensing pad of claim 8, wherein an amount ofthe powder present is a unit dose.
 12. The powder dispensing pad ofclaim 8, wherein the powder is a cosmetic powder.
 13. The powderdispensing pad of claim 8, wherein the powder is a medicated powder.14-19. (canceled)
 20. The powder dispensing pad of claim 3, wherein: anamount of the powder present is a unit dose, the holes have a diameterof 4 to 6 mm the pores have a diameter of 0.8 to 1.25 mm, and athickness of the storage layer is 2 to 4 mm.
 21. A packaged set ofpowder dispensing pads, comprising: a pad dispenser, and a plurality ofthe powder dispensing pads of claim 1, in the pad dispenser.
 22. Amethod of applying powder, comprising: applying a single dose of thepowder from the powder dispensing pad of claim 8, and discarding thepowder dispensing pad.
 23. A method of making the powder dispensing padof claim 1, comprising: placing the powder on the bottom barrier layer;placing astorage layer on the bottom barrier layer, on the powder;placing the metering layer on the storage layer; placing the top barrierlayer on the metering layer; forming the seal, by pressing the topbarrier layer against the bottom barrier layer and applying heat; andsealing the holes in the top barrier layer by placing the sealing layeron the top barrier layer.
 24. A powder dispensing pad containing a unitdose of powder. 25-26. (canceled)
 27. A packaged set of powderdispensing pads, comprising: a pad dispenser, and a plurality of thepowder dispensing pads of claim 24, in the pad dispenser.
 28. A packageset of powder dispensing pads, comprising a plurality of the powderdispensing pads of claim
 24. 29-30. (canceled)